U.S. patent number 6,808,198 [Application Number 10/104,209] was granted by the patent office on 2004-10-26 for pillar-mounted frontal airbag.
This patent grant is currently assigned to Autoliv ASP, Inc.. Invention is credited to Steven R. Fredin, David W. Schneider.
United States Patent |
6,808,198 |
Schneider , et al. |
October 26, 2004 |
Pillar-mounted frontal airbag
Abstract
A pillar-mounted airbag module is disclosed. The frontal airbag
module of the invention includes an airbag cushion configured to be
deployed from a pillar of a vehicle and an airbag inflator coupled
to the airbag cushion, the airbag inflator being suitable for
attachment to a pillar of a vehicle. The frontal airbag module of
the invention is configured to deploy the airbag cushion laterally
along a windshield of the vehicle and then to subsequently inflate
the airbag cushion toward the vehicle occupant.
Inventors: |
Schneider; David W. (Waterford,
MI), Fredin; Steven R. (Djursholm, SE) |
Assignee: |
Autoliv ASP, Inc. (Ogden,
UT)
|
Family
ID: |
28040533 |
Appl.
No.: |
10/104,209 |
Filed: |
March 20, 2002 |
Current U.S.
Class: |
280/730.1;
280/743.1 |
Current CPC
Class: |
B60R
21/237 (20130101); B60R 21/213 (20130101) |
Current International
Class: |
B60R
21/16 (20060101); B60R 21/20 (20060101); B60R
021/22 () |
Field of
Search: |
;280/730.1,730.2,736,743.1,743.2,728,728.2 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Dunn; David R.
Attorney, Agent or Firm: Brown; Sally J.
Claims
What is claimed and desired to be secured by United States Letters
Patent is:
1. An airbag module for protecting a vehicle occupant, the airbag
module comprising: an inflator; and an airbag cushion having an
inflation orifice, wherein the inflator is coupled to the airbag
cushion at the inflation orifice, the airbag module being adapted
to be installed into a side pillar of a vehicle; wherein the airbag
cushion is sufficiently elongated in shape and folded such that
when the airbag module is installed in a side pillar of a vehicle,
initiation of the inflator causes the airbag cushion to first
inflate substantially laterally along a windshield of the vehicle
between a vehicle occupant and a structure of the vehicle, and to
subsequently inflate the airbag cushion substantially toward the
vehicle occupant.
2. The airbag module of claim 1, wherein the airbag cushion
comprises an upper panel coupled to a central panel that is coupled
to a lower panel, wherein one of said panels includes the inflation
orifice.
3. The airbag module of claim 2, wherein the inflation orifice is
positioned in the central panel of the airbag cushion.
4. The airbag module of claim 3, wherein the inflation orifice
comprises a narrowed throat region of the airbag cushion.
5. The airbag module of claim 1, wherein the airbag module is
adapted to be installed into the A-pillar of the vehicle.
6. The airbag module of claim 1, wherein the airbag module is
adapted to be installed into the B-pillar of the vehicle.
7. The airbag module of claim 1, wherein the airbag module is
adapted to be installed into the C-pillar of the vehicle.
8. The airbag module of claim 1, further comprising a vehicular
trim panel.
9. The airbag module of claim 1, wherein the airbag cushion is a
driver's side airbag.
10. The airbag module of claim 1, wherein the airbag cushion is a
passenger's side airbag.
11. The airbag module of claim 1, further comprising at least one
tether to help properly position the airbag cushion during
inflation.
12. The airbag module of claim 1, wherein the airbag inflator is
substantially cylindrical in shape.
13. The airbag module of claim 1, wherein the airbag cushion is
folded according to a method comprising the steps of: providing an
elongated airbag having an inflation orifice on an outer edge of
the airbag cushion, the airbag cushion comprising an upper panel, a
lower panel, and a central panel; flattening said airbag by drawing
the inflation orifice in a first direction and flattening the
central panel moving away from the inflation orifice such that the
central panel comprises a transverse fold at an end opposite the
inflation orifice and the upper and lower panels are longitudinally
folded; tucking the upper and lower panels inwardly toward the
central panel to form at least one longitudinal pleat; and folding
the airbag transversely beginning at the end opposite the inflation
orifice to form at least one transverse fold, wherein said method
of folding renders the airbag suitable for deployment from a
vehicle pillar.
14. The airbag module of claim 13, wherein the method of folding an
airbag results in at least two longitudinal pleats.
15. The airbag module of claim 13, wherein the method of folding an
airbag results in at least two transverse folds.
16. An airbag module for protecting a vehicle occupant, the airbag
module comprising: an inflator; and an airbag cushion having a
mounting face, a contact face, and an inflation orifice, the
mounting face being situated at an angle to the contact face, and
the inflation orifice being positioned on said mounting face,
wherein the inflator is coupled to the airbag cushion at the
inflation orifice, the airbag module being adapted to be installed
into a side pillar of a vehicle; wherein upon initiation of the
inflator when the airbag module is folded and installed in a side
pillar of a vehicle, the airbag cushion is caused to first inflate
substantially laterally alone a windshield of the vehicle between a
vehicle occupant and a structure of the vehicle and to subsequently
deploy the airbag cushion substantially toward the vehicle
occupant.
17. The airbag module of claim 16, wherein the airbag cushion
comprises an upper panel coupled to a central panel which is
coupled to a lower panel.
18. The airbag module of claim 17, wherein the central panel of the
airbag cushion comprises the inflation orifice.
19. The airbag module of claim 18, wherein the inflation orifice
comprises a narrowed throat region of the airbag cushion.
20. The airbag module of claim 16, wherein the airbag module is
adapted to be installed into the A-pillar of the vehicle.
21. The airbag module of claim 16, wherein the airbag module is
adapted to be installed into the B-pillar of the vehicle.
22. The airbag module of claim 16, wherein the airbag module is
adapted to be installed into the C-pillar of the vehicle.
23. The airbag module of claim 16, further comprising a vehicular
trim panel.
24. The airbag module of claim 16, wherein the airbag cushion is a
driver's side airbag.
25. The airbag module of claim 16, wherein the airbag cushion is a
passenger's side airbag.
26. The airbag module of claim 16, further comprising at least one
tether to help properly position the airbag cushion during
inflation.
27. The airbag module of claim 16, wherein the airbag inflator is
substantially cylindrical in shape.
28. The airbag module of claim 16, wherein the airbag cushion is
folded according to a method comprising the steps of: providing an
elongated airbag having an inflation orifice on an outer edge of
the airbag cushion, the airbag cushion comprising an upper panel, a
lower panel, and a central panel; flattening said airbag by drawing
the inflation orifice in a first direction and flattening the
central panel moving away from the inflation orifice such that the
central panel comprises a transverse fold at an end opposite the
inflation orifice and the upper and lower panels are longitudinally
folded; tucking the upper and lower panels inwardly toward the
central panel to form at least one longitudinal pleat; and folding
the airbag transversely beginning at the end opposite the inflation
orifice to form at least one transverse fold, wherein said method
of folding renders the airbag suitable for deployment from a
vehicle pillar.
29. The airbag module of claim 28, wherein the method of folding an
airbag results in at least two longitudinal pleats.
30. The airbag module of claim 28, wherein the method of folding an
airbag results in at least two transverse folds.
31. An airbag module for protecting a vehicle occupant, the airbag
module comprising: an elongated airbag cushion having an inflation
orifice located on an outer edge of the airbag cushion; and an
airbag inflator coupled to the inflation orifice of the airbag
cushion, the airbag inflator being suitable for attachment to a
side pillar of a vehicle; wherein when installed in a side pillar
of a vehicle, the airbag is folded such that initiation of the
inflator causes the airbag cushion to first inflate substantially
laterally along a windshield of the vehicle and then to
subsequently inflate substantially toward the occupant.
32. The airbag module of claim 31, wherein the elongated airbag
cushion comprises an upper panel, a lower panel, and a central
panel.
33. The airbag module of claim 32, wherein the airbag cushion is
configured to be a driver's side airbag cushion.
34. The airbag module of claim 32, wherein the airbag cushion is
configured to be a passenger's side airbag cushion.
35. The airbag module of claim 32, wherein the central panel of the
airbag further comprises the inflation orifice.
36. The airbag module of claim 31, wherein the airbag module
further comprises a trim panel.
37. The airbag module of claim 31, wherein the airbag inflator is
substantially cylindrical.
38. The airbag module of claim 31, wherein the airbag module
further comprises at least one tether to help properly position the
airbag cushion during inflation.
39. The airbag module of claim 31, wherein the airbag cushion is
folded according to a method comprising the steps of: providing an
elongated airbag having an inflation orifice on an outer edge of
the airbag cushion, the airbag cushion comprising an upper panel, a
lower panel, and a central panel; flattening said airbag by drawing
the inflation orifice in a first direction and flattening the
central panel moving away from the inflation orifice such that the
central panel comprises a transverse fold at an end opposite the
inflation orifice and the upper and lower panels are longitudinally
folded; tucking the upper and lower panels inwardly toward the
central panel to form at least one longitudinal pleat; and folding
the airbag transversely beginning at the end opposite the inflation
orifice to form at least one transverse fold, wherein said method
of folding renders the airbag suitable for deployment from a
vehicle pillar.
40. The airbag module of claim 39, wherein the method of folding an
airbag results in at least two longitudinal pleats.
41. The airbag module of claim 39, wherein the method of folding an
airbag results in at least two transverse folds.
42. A method of decelerating a vehicle occupant during a collision
event comprising deploying an elongated airbag cushion having an
inflation orifice on a lateral face of the airbag cushion from a
side pillar of a vehicle, wherein the airbag cushion deploys by
first inflating substantially laterally along a windshield of the
vehicle between the vehicle occupant and a structure of the
vehicle, and then to subsequently inflate the airbag cushion
substantially toward the vehicle occupant.
43. The method of claim 42, wherein the airbag cushion is deployed
from the A pillar of the vehicle.
44. A method of decelerating a vehicle occupant during a collision
event comprising the steps of: providing an airbag module
comprising an elongated airbag cushion having an inflation orifice
on a lateral face of the airbag cushion and an airbag inflator
coupled to the airbag cushion, the airbag inflator being configured
to be attached to a pillar of a vehicle; installing the airbag
module in the pillar of a vehicle; and deploying the airbag cushion
from the pillar of a vehicle during a collision event, wherein the
airbag cushion first inflates substantially laterally along a
windshield of the vehicle between a vehicle occupant and a
structure of the vehicle and then subsequently inflates the airbag
cushion substantially toward the vehicle occupant.
45. The method of claim 44, wherein the pillar is the A pillar of
the vehicle.
46. The method of claim 44, wherein the airbag cushion comprises an
upper panel, a central panel, and a lower panel.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to inflatable airbags for protecting
vehicle occupants during collision events. More specifically, the
present invention relates to an airbag module configured to be
installed in a support pillar of a vehicle.
2. Description of Related Art
Inflatable airbags enjoy widespread acceptance as passive passenger
restraints for use in motor vehicles. Airbags have built a
reputation of preventing numerous deaths and injuries over years of
development, testing, and use. Studies show that in some instances,
the use of frontally placed vehicular airbags can reduce the number
of fatalities in head-on collisions by 25% among drivers using seat
belts and by more than 30% among unbelted drivers. Other statistics
suggest that in a frontal collision, the combination of a seat belt
and an airbag can reduce the incidence of serious chest injuries by
65% and the incidence of serious head injuries by up to 75%. These
numbers and the thousands of prevented injuries they represent
demonstrate the life-saving potential of airbags and the need to
encourage their use, production, and development.
In part as a result of benefits such as those described above,
automakers are now required to install airbags in most new vehicles
manufactured for sale in the United States. Many automobile
manufacturers have turned this airbag technology requirement into a
marketing tool. Enticed by the promise of added safety, vehicle
purchasers frequently seek out vehicles with sophisticated airbag
systems.
Airbags are often installed in the steering wheel and in the
dashboard on the passenger's side of a car. These airbags are often
large and thick because airbags are used for the primary
deceleration of a vehicle occupant. In a large percentage of
collisions the occupant is accelerated forward through the vehicle.
Frontal airbags are generally constructed to inflate toward the
vehicle occupant, often with significant force. Airbag systems are
generally designed to protect an occupant in a specific space
within the car in a specific set of predicted positions. When a
vehicle occupant is not positioned in a predicted position,
deployment of the airbag may cause injury to the occupant.
Frontal airbags are generally housed within the dashboard, steering
wheel, or other similar interior panels of a vehicle, and are
covered by a trim cover panel. The trim cover panel covers the
compartment that contains the airbag module. Such airbag covers are
typically made of rigid plastic, and are configured to open by the
pressure from the deploying airbag. During deployment of the
airbag, it is preferable to retain the airbag cover in at least
partial attachment to the vehicle to prevent the airbag cover from
flying loose in the passenger compartment. If the airbag cover were
allowed to detach and freely move into the passenger compartment,
it could cause injury to a passenger.
Airbags are generally linked to a control system within the vehicle
that triggers their initiation when a collision occurs. This
control system is often referred to as an electronic control unit
(or "ECU"). The ECU includes a sensor that continuously monitors
the acceleration and deceleration of the vehicle. This information
is sent to a processor which processes it using an algorithm to
determine if a deceleration experienced by the vehicle is a
collision or not. If this accelerometer measures an abnormal
deceleration, such as one caused by a collision event, it triggers
the ignition of an airbag inflator.
When the processor of the ECU determines, based on a set of
pre-determined criteria, that the vehicle is experiencing a
collision, the ECU transmits an electrical current to an initiator
assembly. The initiator assembly is in turn connected to an
inflator that is coupled to the airbag module. The initiator
activates the inflator. An inflator is a gas generator that
typically uses a compressed or liquefied gas or mixture of gases, a
solid fuel, or some combination of the two, to rapidly generate a
large volume of inflation gas. This inflation gas is then
channeled, often through a segment of specialized tubing called a
gas guide, to the airbag. The gas inflates the airbag, allowing it
to absorb the impact of the vehicle occupants and thus prevent
possible injury.
Following the activation of the airbag system and the deceleration
of any vehicle occupants, the airbags rapidly deflate to release
the vehicle occupants. Some airbags may be fully inflated within 50
thousandths of a second, and subsequently deflated within two
tenths of a second.
As experience with the manufacture and use of airbags has
progressed, the engineering challenges involved in their design,
construction, and use have become better understood. First, most
airbag systems are designed to rapidly inflate and provide a
cushion in front of or alongside an occupant based on a presumption
that the occupant will be in a predetermined position. Problems
have been noted to occur when the occupant is "out of position"
with regard to this presumed placement when a collision event
occurs and the airbag deploys. Similarly, problems may occur when
the occupant, though possibly at first in the predicted position,
strikes a glancing blow to the airbag, and is then deflected out of
the airbag before proper deceleration can occur.
Other out-of-position injuries occur when an occupant is positioned
within the inflation path of the airbag. In such cases, the
occupant may be struck by the airbag when it inflates, in some
cases causing substantial injury to the occupant. Airbags currently
used in the art inflate with significant force in order to be
inflated and in place in a very short period of time. Part of the
problem may be attributed to the fact that most airbags inflate
directly toward the occupant.
Additional problems in airbag use involve effective coverage of
potential impact surfaces of a vehicle interior by airbags. Many of
the known airbags effectively protect the occupant from contact
with regions of the dashboard, the windshield, and often, the
steering wheel. One area more difficult to protect traditionally
has been the vehicle's A-pillar. This rigid pillar carries
potential to cause serious injury to a vehicle occupant during a
collision event.
Other problems faced in the development and use of airbags include
costs encountered in providing a proper housing and attachment for
airbags. Many dashboard- and steering wheel-mounted airbags require
the use of housings separate from the structure of the vehicle
itself for convenient use, thus raising the cost of use of the
airbags. It would be an advancement in the art to provide an airbag
mounted and housed within the structure of the vehicle to reduce
the cost of airbags.
Finally, with airbags mounted in dashboards, doors, steering
wheels, etc., considerable damage is often caused to the mounting
panel by deployment of the airbag. Specifically, in
dashboard-mounted systems, deployment often causes sufficient
damage to the instrument panel of the vehicle to merit complete
replacement.
Accordingly, the need exists for a pillar-mounted frontal airbag
system to better protect a vehicle occupant. Such a system could
protect the vehicle occupant in a wide variety of collision events,
including those requiring better shielding of the A-pillar.
Specifically, it would be an advancement in the art to provide a
pillar-mounted frontal airbag suitable for mounting in a vehicle in
the A-pillar of the vehicle, the airbag module requiring reduced
housing and attachment means and reducing the need for instrument
panel replacement after airbag deployment. Finally, it would be an
advancement in the art to provide an airbag which reduces the
incidence of out-of-position injuries by deploying first along the
dashboard of a vehicle, and then deploying toward the occupant,
thus contacting the occupant (if at all) with greatly reduced
inflation force. Such a device is disclosed and claimed herein.
SUMMARY OF THE INVENTION
The apparatus of the present invention has been developed in
response to the present state of the art, and in particular, in
response to the problems and needs in the art that have not yet
been fully solved by currently available airbag modules. Thus, it
is an overall objective of the present invention to provide a
pillar-mounted airbag module for protecting a vehicle occupant.
To achieve the foregoing objective, and in accordance with the
invention as embodied and broadly described herein in the preferred
embodiment, a frontal airbag module for protecting a vehicle
occupant is provided. The airbag module may include an inflator,
and an airbag cushion having an inflation orifice, wherein the
inflator is coupled to the airbag cushion at the inflation orifice.
The airbag module is adapted to be installed into a side pillar of
a vehicle. The airbag cushion is in some embodiments sufficiently
elongated in shape such that when the airbag is installed in a side
pillar of a vehicle, initiation of the inflator deploys the airbag
cushion between a vehicle occupant and a structure of the
vehicle.
The airbag cushion may be elongate in shape. Specifically, the
airbag cushion may be made elongated in shape such that when it
inflates, it reaches from its site of installation, such as the
A-pillar, to the center of the vehicle. Additionally, the inflation
orifice may be placed at an end of the airbag which is used for
mounting the airbag.
The airbag cushion may be constructed of multiple panels.
Specifically, the cushion may comprise an upper panel, a lower
panel, and a central panel. The central panel of such an airbag
cushion may additionally include an inflation orifice. This
inflation orifice may simply comprise a narrowed throat region of
the airbag.
According to the present invention, the frontal airbag module may
include an airbag cushion configured to be a driver's side airbag
cushion. Such a module would be installed in the A-pillar nearest
the seat of the vehicle driver. Alternatively, the frontal airbag
module of the present invention may include an airbag cushion
configured to be a passenger's side airbag cushion. Such a module
would be installed in the A-pillar nearest the seat of the
front-seat passenger. The invention may also be made suitable for
use in the other pillars of a vehicle, such as the B, C, and D
pillars.
Additionally, the frontal airbag module of the invention further
may comprise at least one tether to assist in the proper
positioning of the airbag cushion upon inflation. Tethers may be
positioned internally within the airbag cushion to direct its
inflation direction, path, and shape, as well as externally to
further direct the inflation path and configuration, as shown in
FIG. 2.
The frontal airbag modules of the invention also include an airbag
inflator for inflating, and thus deploying, the airbag cushion
briefly described above. Such an inflator may be substantially
cylindrical in shape so as to be most easily accommodated within
the pillar of the vehicle. Additionally, the airbag inflator may be
either a single-stage airbag inflator or a dual-stage airbag
inflator.
The pillar-mounted frontal airbag module of the invention may also
include a trim panel. The trim panel is configured to be attached
to the other components of the airbag module as well as to the
pillar of the vehicle to which the assembly is to be mounted. This
trim panel encloses the airbag and inflator. The trim panel also
serves to allow the airbag to be integrated into the vehicle in a
visually pleasing manner, since the trim panel can be constructed
of materials similar in color and texture to those used in the
interior of the vehicle in which the airbag is to be installed.
The trim panel of the airbag module is constructed to release the
airbag upon initiation of the inflator, thus deploying the airbag
into the cabin of the vehicle in a position in front of a vehicle
occupant. This may be accomplished in several ways. The trim panel
could be made releasable by equipping the trim panel with hinges
and a releasable latch. Alternatively, the trim panel could be
constructed so as to predictably rupture in such a manner that the
airbag would be properly deployed. This could be accomplished by
providing a trim panel with frangible portions such as a scored or
perforated internal surface.
In addition to the features discussed above, it should be noted
that the airbag module of the present invention is unique in its
configuration, mounting location in a vehicle, and deployment
method. Specifically, the airbag is configured to be installed
completely within the A-pillar of a vehicle. The inflator and
airbag nest within the A-pillar, and are releasably enclosed by the
trim panel. By including the inflator within the A-pillar, the need
for a gas guide or other similar intermediate tube between the
inflator and the airbag itself is avoided. This may reduce the
expense associated with manufacturing and installing the
airbag.
In addition to the above-mentioned benefits, installation of the
airbag module completely within the A-pillar allows increased
flexibility in the design of the instrument panel, steering wheel,
driver's side and passenger's side of the vehicle. Specifically, by
removing the airbag module--both the airbag cushion and the airbag
inflator--from the dashboard, space is left to add either
additional features to the dashboard/instrument panel/glove
compartment of the vehicle or to add greater flexibility to the
design of the dashboard. Furthermore, the overall mass of inflator
portion of the airbag module may be reduced in this scenario since
the structure of the A-pillar eliminates the need for attachment
brackets and additional securing reinforcements.
In addition, by removing the airbag from the instrument panel, the
costs associated with repairing a vehicle after airbag deployment
may be reduced by lowering the need for instrument panel
replacement due to damage caused by airbag deployment.
The pillar-mounted airbag of the invention deploys when activated
by a control unit linked to the inflator of the module. The airbag
inflator is directly linked to the airbag cushion of the module.
When activated, the inflator begins rapidly producing inflation
gas, thus creating high internal pressures within the airbag
module. At this point, the trim panel releases the airbag, either
by opening along a hinged region, or by rupturing in a predictable
manner. In either case, the folded airbag is deployed, thus
allowing it to be inflated by the pressurized inflation gas being
rapidly produced by the inflator.
The airbag cushion of the present invention is novel in that it is
configured to deploy first laterally along a windshield toward the
center of the vehicle in which it is installed, and then to
subsequently inflate toward the occupant. More particularly, the
airbag first inflates toward the center of the vehicle along the
dashboard. Next, the airbag begins to expand outwardly toward the
back of the vehicle. As this expansion continues, the airbag is
deflected away from the windshield, and begins to swing outwardly
away from the windshield. This, in addition to the expansion of the
cushion backward toward the occupant, assists in properly
positioning the cushion for use.
The airbag cushion of the invention is thus positioned in the
A-pillar to deploy to prevent a vehicle occupant from striking a
surface in front of the occupant such as a dashboard, steering
wheel, or windshield. By deploying in this manner, much of the
initial force with which the airbag is inflated is directed along a
vector away from the occupants of the vehicle. This function
reduces the possibility of airbag-caused injury to the vehicle
occupant, and may additionally reduce the severity of such injuries
when they do occur. This configuration further acts to prevent
out-of-position injuries to a vehicle occupant by sweeping toward
the occupant, as well as by being inflated toward the occupant more
gently. Finally, the airbag module of the invention improves the
coverage of the A-pillar by preventing possible occupant contact
with the A-panel during a collision event.
These and other objects, features, and advantages of the present
invention will become more fully apparent from the following
description and appended claims, or may be learned by the practice
of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above recited and other
advantages and objects of the invention are obtained will be
readily understood, a more particular description of the invention
briefly described above will be rendered by reference to specific
embodiments thereof that are illustrated in the appended drawings.
Understanding that these drawings depict only typical embodiments
of the invention and are not therefore to be considered to be
limiting of its scope, the invention will be described and
explained with additional specificity and detail through the use of
the accompanying drawings in which:
FIG. 1 is a perspective view of airbag modules of the invention
shown mounted and inflated in a vehicle;
FIG. 2 is a cross sectional view of a vehicle showing an airbag
module of the invention mounted and inflated in the vehicle in
relation to a vehicle occupant;
FIG. 3 is a cross-sectional view of the pillar-mounted frontal
airbag system of the invention taken at line 3--3 of FIG. 2, shown
in its stowed, compact configuration and in its deployed
configuration (in phantom); and
FIG. 4 is a side perspective view of an airbag of the invention
shown flattened in preparation for folding;
FIG. 5 is a side perspective view of an airbag of the invention
having further folds to illustrate an intermediate step in the
folding of the airbag prior to its insertion into an A-pillar of a
vehicle;
FIG. 6 is a cross sectional view of the partially-folded airbag of
FIG. 5 taken at line 6--6; and
FIG. 7 is a side perspective view of the airbag of FIG. 5
exhibiting the folds resulting from the final folding step.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The presently preferred embodiments of the present invention will
be best understood by reference to the drawings, wherein like parts
are designated by like numerals throughout. It will be readily
understood that the components of the present invention, as
generally described and illustrated in the figures herein, could be
arranged and designed in a wide variety of different
configurations. Thus, the following more detailed description of
the embodiments of the apparatus, system, and method of the present
invention, as represented in FIGS. 1 through 7, is not intended to
limit the scope of the invention, as claimed, but is merely
representative of presently preferred embodiments of the
invention.
Referring now to FIG. 1, a vehicle 22 including pillar-mounted
airbag systems according to the invention is shown. More
specifically, the vehicle 22 is shown including the pillar-mounted
frontal airbag system 10a of the invention in the driver's side
A-pillar 24 and the system 10b similarly mounted in the passenger's
side A-pillar 26. Here, the airbag cushions 40a and 40b of the
system 10 are shown deployed and inflated.
The systems 10a and 10b are shown in FIG. 1 mounted in the driver's
side A-pillar 24 and the passenger's side A-pillar 26. The systems
10a, 10b include an inflator 120, an airbag cushion 40a, 40b, and a
trim panel (not shown). The airbag cushion 40a, 40b of the
invention comprises an upper panel 50, a central panel 70, and a
bottom panel 90. The upper panel 50 has a shape configured to
conform to the windshield 18 of a vehicle along a back edge (not
shown) of the upper panel 50. The upper panel 50 is attached to the
central panel 70 along its periphery by upper peripheral seam 54.
The airbag cushions 40a, 40b are thus seen to be elongated, as is
portrayed in FIG. 1, such that each nearly stretches to the center
of the dashboard, or vehicle. By being elongated thus, the airbags
are made to be able to better protect vehicle occupants in a wider
range of positions.
Additionally, the airbag cushions 40a, 40b additionally include an
inflation orifice which is not shown in FIG. 1 for clarity.
Visible, however, is that in FIG. 1, the airbag cushions 40a, 40b
are attached to the inflators 120 on a side of the airbag cushions.
This side is designated the mounting face of the cushion, and is
preferably the site of the inflation orifice on the airbag cushion.
The front face of the airbag cushion 40a, 40b intended for contact
by the occupants is designated the contact face. This mounting face
is located on a plane different from the contact face. In some
embodiments, the mounting face is substantially perpendicular to
the contact face.
The central panel 70 is preferably an elongate panel that is
configured to be sewn into a loop. An upper edge of the central
panel 70 is attached to the upper panel 50 at the upper peripheral
seam 54; and a lower edge of the central panel 70 is attached to
the lower panel 90 at a lower peripheral seam 94. The central panel
70 may be configured to control, in large part, the shape of the
inflated airbag cushion 40a, 40b. Specifically, the central panel
70 may be configured such that when it is attached to the upper and
lower panels 50, 90, it forms a loop. The central panel 70 may be
shaped so as to provide a loop with a small width along its back
face (not shown), which contacts the windshield 18 of the vehicle
22, and larger width along its front, or occupant-facing, face 80.
In some variants of the airbag cushion 40 of the invention, this
front face 80 of the central panel 70 is configured to be the panel
primarily impacted by a vehicle occupant during a collision
event.
The central panel 70 also generally includes an inflation orifice
72, to which an inflator 120 is attached, and through which
inflation gases enter the airbag cushion 40a, 40b upon initiation
of the inflator 120. The size and shape of the inflation orifice
may be configured in various ways to influence the inflation rate,
speed, and direction of the airbag during deployment. In some
presently preferred embodiments of the pillar-mounted frontal
airbag system of the invention, the inflation orifice 72 of the
central panel 70 further includes a narrowed throat region 74,
which extends outwardly from the central panel 70 to the inflator
120. This narrowed throat region 74 allows for space and more free
movement between the A-pillar 24, 26 and the airbag cushion 40a,
40b. This narrowed throat region 74 may be formed by the ends of
the central panel 70, or may alternatively be constructed from
entirely separate components suitable for use in attaching the
airbag and conducting inflation gas. The inflation orifice 72 may
alternatively be placed in the upper and lower panels 50, 90.
The lower panel 90 of the airbag cushion 40 is designed to
primarily contact the dashboard 14 and steering wheel 12 of the
vehicle 22 and to place the front face 80 of the central panel 70
in proper position for contact by the vehicle occupant during a
collision event. Similarly, the airbag cushion 40b deploying from
the A-pillar 26 of the passenger's side of the vehicle has a bottom
panel 90. This panel 90 is designed to contact the dashboard 14 of
the vehicle and place the central panel 70 of the cushion 40 in a
position such that the vehicle occupant would strike the central
panel 70 in a collision event. The cushion 40b also has an upper
panel 50 configured to contact the windshield 18 and direct the
inflation of the cushion 40b outwardly toward the vehicle
occupant.
Referring now to FIG. 2, a cross sectional view of a vehicle 22
showing an airbag module 10 of the invention mounted and inflated
in the vehicle is shown. This figure shows the position of the
module 10 and the airbag 40 in relation to a vehicle occupant 28.
The figure also shows the movement of inflation gases 42 within the
airbag 40 as they travel first outward along the dashboard 14 and
windshield 18, and then are diverted toward the back of the vehicle
22 and the occupant 28 located in front seat 16. The airbag module
10 is mounted in A pillar 26.
FIG. 3 shows a cross sectional view of an airbag module of the
invention taken at line 3--3 of FIG. 2. In this figure, the airbag
cushion 40 is depicted in both its stowed, compact configuration,
and then partially (in phantom) in its deployed configuration.
The airbag cushion 40 is first shown deflated, folded, and stowed
in chamber 116. This chamber 116 is defined on one side by pillar
wall 111 and inner panel 113, and on the other by trim panel 110.
Trim panel 110, inner panel 113, and pillar wall 111 unite to form
A-pillar 24, 26. This is accomplished on one side by attaching a
hinge region 112 of the trim panel 110 to the inner panel 113 and
the pillar wall 111 by an attachment pin 114a. On the other side, a
closure region of the trim panel 118a, here shown as a
ball-in-socket closure, is releasably joined with a closure region
of the inner panel 118b. Other suitable fasteners known in the art
may be used. The inner panel 113 is joined to the pillar wall 111
by a second attachment pin 114b.
The airbag cushion 40 is attached to the inflator 120, via the
inflation orifice 72. This may be accomplished using a variety of
means known in the art, including positioning the inflator 120 over
the inflator orifice 72, and fastening edges of the inflation
orifice 72 around the back of the inflator 120 to a stud (not
shown) and securing them with a bolt (not shown). The inflator 120
of the invention may be a single- or dual-stage inflator, and may
use solid, liquid, and gaseous inflation gas generants, including
pressurized gases and mixtures of gases in any combination (not
shown).
In operation, the inflator 120 is initiated, thus expelling
inflation gases into the airbag cushion 40, which begins to expand
and inflate. The increase in pressure caused by this expansion
eventually becomes sufficient to open the closure regions 118a,
118b of the inner panel 113 and the trim panel 110. After this, the
trim panel 110 swings open, flexing along hinge region 112, as
shown in FIG. 3 in phantom. This allows the airbag cushion 40 to
inflate (partially shown in phantom).
The pillar-mounted frontal airbag system 10 is configured to be
installed in A-pillars 24, 26; here shown to be made up of pillar
wall 111, inner panel 113, and trim panel 110. These act to enclose
the system 10. In this way, the system 10 occupies space that may
otherwise go unused within the pillar 24, 26. The airbag system of
the invention may also be configured to be installed in and
deployed from other vehicular pillars such as the B pillars, C
pillars, and D pillars. The system may be installed in the pillar
using any of a variety of means known in the art, including, but
not limited to, the use of tabs which can be bolted to the pillar
structure, and snap-in fastening systems.
FIGS. 4 through 7 schematically show steps of a preferred method of
folding the airbag of the invention to assist in proper deployment
of the airbag cushion 40 along the dashboard 14 of the vehicle 22
toward the center of the vehicle 22, and then toward the vehicle
occupant 28. FIG. 4 shows the airbag 40, having upper panel 50,
central panel 70, and lower panel 90, flattened, thus placing
longitudinal folds in the upper panel 50 and the lower panel 90,
and transverse folds in all three panels 50, 70, 90. As noted
briefly above, the upper panel 50 is joined to the central panel 70
via the upper peripheral seam 54. The lower panel 90 is joined to
the central panel 70 via the lower peripheral seam 94. The central
panel 70 is shown here to include an inflation orifice 72 having a
narrowed throat region 74.
FIG. 5 shows that in a subsequent folding step, the upper and lower
panels 50, 90 are pleated longitudinally to form pleats 134.
According to the invention, any suitable number of longitudinal
pleats 134 may be used, but a number of longitudinal pleats from
about one to about twenty is generally used, with from about 2 to
about 8 longitudinal pleats being preferred. FIG. 5 further shows
(in phantom) the transverse folds 136 added in the final folding
step of the folding method.
FIG. 6 shows a cross-sectional view of the longitudinally pleated
airbag 40 of FIG. 4 taken at line 6--6. In this figure, the airbag
cushion 40 is shown folded such that the center panel 70 faces
outwardly and the upper panel 50 and the lower panel 90 are folded.
Specifically, the upper panel 50 and the lower panel 90 have
longitudinal pleats 134. In this figure, each of the panels 50, 90
has two complete longitudinal pleats 134. These panels 50, 90 may
alternatively comprise higher numbers of pleats to provide a more
narrow, tubular product. Some cushions 40 have between 2 and 12
pleats, others have between 3 and 8 pleats, and still others have
between 4 and 6 pleats.
FIG. 7 shows a final step in the folding of the airbag cushion 40
of the invention. Specifically, the longitudinally pleated airbag
of FIGS. 5 and 6 is here shown, having been transversely
accordion-folded so as to guide proper inflation and allow the
airbag 40 and inflator to be mounted within the chamber 116. FIG. 7
shows the longitudinal folds 134, the transverse folds 136, the
narrowed throat region 74, and the inflation orifice 72.
The invention comprises a unique frontal airbag module with an
alternative mounting location in the vehicle. The airbag module is
attached to the pillar on the driver or passenger side of the
vehicle. In preferred embodiments of the invention, the airbag
module is configured to be mounted within the A-pillars of the
vehicle. In alternative embodiments, however, the module may be
configured to be mounted and deployed from other vehicle pillars
such as, for example, the B, C, and D pillars. Upon receiving a
signal from the airbag ECU, the airbag is triggered and initially
inflates laterally along the windshield prior to inflating toward
the occupant. This inflation sequence is beneficial for
out-of-position occupants because the deployment forces are not
directed toward the occupant, as with traditional airbags. A
further advantage of this invention is the improved coverage of the
A-pillar by the frontal airbag, to prevent occupant contact with a
rigid pillar during a crash. The deployment pattern reduces the
potential of the occupant to be out-of-position, and also reduces
the potential of injury if the occupant is caught
out-of-position.
Attachment to the A-pillar also allows increased flexibility in the
design of the instrument panel (or steering wheel on the driver
side). In addition, by using the structural A-pillar for module
attachment, a reduction in overall mass can be achieved due to the
elimination of airbag mounting brackets and reinforcements,
normally required for sustaining the airbag deployment forces.
Another advantage of the pillar-mounted airbag is the reduction in
instrument panel replacement due to damage caused by airbag
employment.
The present invention may be embodied in other specific forms
without departing from its structures, methods, or other essential
characteristics as broadly described herein and claimed
hereinafter. The described embodiments are to be considered in all
respects only as illustrative, and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims,
rather than by the foregoing description. All changes that come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *